Note: Descriptions are shown in the official language in which they were submitted.
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1 The present invention relates to a process
for preparation of lightweight, insulating, supple, riyid
or half-rigid elements, as well as to the elements
resulting from such process.
Such elements are panels or parts o~ variable
shapes and thicknesses. Thus, this definition comprises
self-carrying elements such as the roof panels, instru-
ment boards, and tablets, linings of car bodies and the
like, used in the automobile industry~ but these examples
have no limitative character.
A great number of processes for obtaining such
elements are known. However, when the known technologies
are implemented, either the resulting elements do not
meet certain conditions such as e.g. density, and/or
rigidity, and/or suppleness, and/or steadiness and/or
mechanical stren~th and/or -thermal stability, and/or
stability of aspect, and the like, thereby implying that
~or obtaining the desired result (s), the process of
preparation must be influenced either during the opera-
tional steps, or relative to the operative conditions,
and/or the nature of the compounds, compositions, and
materials used, or the processes are relatively complex
and/or little economical, when they are used to obtain
finished elements possessing well defined properties and
characteristics.
The invention now solves both types of difficul-
ties by a simple and economical process which permits to
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1 obtain as desired under the same operatlonal conditions,
a complete range of finished products from the supple to
the rigid ones, inclusive of the half-supple and the
hal-f-rigid~
The process according to the invention consists
of impregnatiny a porous supple material having an
internal structure with preferably open cells, with the
desired quantity of a solution of a compound selected
from the group comprising isocyanates and having consequ-
ently at least one -NCO group in its formula, said
material having already or not having the final shape
which is to be obtained, then proceeding with reticulation
of said compound after reacting it with water, producing a
derivative of urea or biuret.
There can be cited, as examples of compounds
belonging to the isocyanate group, the isocyanates them-
selves (pure or raw) such as TDI (toluene di-isocyanate)
or MDI (4-4'-diphenylmethane di-isocyanate), the polymers
of isocyanates still containing at least one termi.nal
-NCO group, and generally, any compounds having at least
one -NCO termination in their molecule.
~ccording to an advantageous form of embodiment,
the desired quantity of the solution of the isocyanate
compound is obtaind by expressing if need be any quantity
of liquid in excess of said desired quantity, from the
totally impregnated porous material.
Similarly, as regards shape to be given to the
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1 desired Einal element, if the basic element i5 not already
of the required shape, it is obtained before or during
reticulation through die-shaping, stamping, rolling,
calendering, moulding, and like operations.
The process according to the invention makes it
possible to realize supple, half-supple, rigid or half-
rigid elements depending on the isocyanate compound used
for the impregnation, with unchanged conditions of
implementation. .As a matter of fact, the reactions of
the isocyanate radicals upon water are ~nown, leading to
derivatives of urea and biuret, which are the more reti-
culated, the more the starting compounds contain -NCO
radicals. This would explain the variety of properties
determining suppleness or rigidity that can thus be
obtained.
According to one mode of implementation which
is interesting for obtaining such elements having a
modified surface aspect starting from the initial aspect,
the impregnation step is followed or accompanied by a
coating step consisting of depositing on one or both of
the faces of the starting element, a fibrous material with
distinct fibers, admitted as separated fibers ~sh~rt or
long) of layers or mats of fibers, with such fibers being
of natural or synthetic, organic or mineral origin, such
as glass fibers, animal or vegetal fibers, synthetic
fibers, and said isocyanate compound being then used as a
bonding or embedding agent for such fibers.
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1 It will be easily understood that such an
implemen-tation mode is interesting because the isocyanate
compound is both the impregnation agent of the cells and
the surfaces of the star~ing porous material element, the
bonding agent (at the interfaces) between the fibers and
said element, on the one hand, and on the other hand,
between the fibers themselves, and the embedding agent for
the fibers, the assembly thus realized after reticulation
constituting a coherent assembly in which the fibers used
intimately belong to the porous element by being embedded
and incorporated therein and also constitute the superfi-
cial layer which is made integral with the surface of
said porous element by intimately belonging thereto.
Similarly, the aspect of the surfaces may still
be modified by providing a coating material of continuous
texture such as sheets of paper, cardboard, layers, webs,
fabrics, films or pellicles of plastics materials, and the
like, said isocyanate compound also serving as a bonding
agent.
It will be understood ~hat the reticulation
reaction can be activated, accelerated, or else modified
as it is known in itself, by adding catalysts or other
accelerators thereto, and/or by heating.
The following example is given in an illustra-
tive not at all limitative manner, in reference to the
attached diagram showing a possible implementation of the
process according to this invention.
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1 - Porous element used (or foam): layer of
cellular polyether of a density of 14 kg/m3, and a -thick-
ness of 7 mm;
-Isocyanate: MDI (4-4'-diphenylmethane di-
isocyanate) in a chlorinated solvent (50!50 by weight);
-Glass fibers of a length of 2 cm;
-Polyethyiene sheet of 25 g/m2;
-Coatings:
on one face: unweft of 200 g/m2,
on the other face: unweft of 50 g/m2.
The foam (M) is impregnated (at 1) bv slop-
padding in the .MDIJsolvent mixture, followed by drying
out ~at la). The setting of the dry out rate is calculated
so as to obtain a material weighing 650 g/m2. During the
lS dry out step~ the foam, due to its swelling, weighs from
98 g/m to 70 g~m , and contains 292 g/m of MDI and 292
g of solvent.
At the exit from the dry out station, water
spraying (advantageously, aminated ~ 20 g/liter of
dimethylamine) is effected (at 2) on both faces of the
foam.
The so treated foam deposits on a polyethylene
film on which 70 g of cut and intermixed glass fibers have
been deposited (at 3). The same deposi;tion step with 70
g of glass fibers is effected (at 4) on the opposite
face of the foam.
A second polyethylene film is deposited (by the
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1 assembly 5) on said glass Eibers.
The so created complex is compressed e.g. by a
double conveyor, as schematized at 6, in such manner that
the MDI/solvent mixture in excess in the foam embeds the
glass fibers. At the exit from the conveyor, hedgehog
means 7 perfora-tes the polyethylene to permit the foam to
recover its initial thickness~
At this stage, there is provided (at 8) for
application of outer coatings and then, through cutting,
(at 9), the dimensions of the blank necessary later are
-obtained.
The complex is then placed e.g. between a male
and female dies (not shown) faithfully reproducing the
configuration of the final element to be made, then is
heated to a temperature to permit melting of the polyethy-
lene. The reticulation period is lower than 90 seconds.
The polyethylene supplies in melting complemen-
tary bonding between the different elements.
The obtained element weighs 800 g/m2 and is
rigid.
~ccording to the same mode of implementation, a
supple or half-rigid elements is made by selecting the
appropriate -NCO termination isocyanate.
Similarly, for low temperature applications, the
polyethylene can be replaced by any other non porous
support to prevent migration of MDI and the basic element
(M) can adhere thereto.
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1 The MDI/solvent mixture can be admixed with
catalys-ts, silicone and other additives, which only influ-
ence the rekiculation times.
The elements produced in accordance with the
process of the invention have the advantage of showing
very good temperature and humid phase stability, due to
the reticulation reaction resulting in temperature irre-
versible and water insoluble products.
It will be understood that the present invention
was only described in a purely explanatory and not limita-
tive manner and that any useful modifications can be made
thereto without departing from its scope as defined in
the appended claims.
